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Operating Manualfor swing sink clamping element

double-acting type 2154-160 / 2154-2002155-160 / 2155-2002156-160 / 2156-200special designs

double-acting type forexternal clamping: 2235-310 / 2235-410

2237-310 / 2237-410special designs 2230-xxxx

Hilma-Rmheld GmbH

Schtzenstrae 74D - 57271 HilchenbachTelephone: +49 (0) 2733/281-0Fax: +49 (0) 2733/281-113Email: [email protected]

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O P E R A T I N G M A N U A L

Table of contents

1.0 General information, safety information and manufacturer's declaration1.1 General1.2 Field of application

1.3 Operating characteristics1.4 Temperatures1.5 Important safety information1.6 Manufacturer's declaration

2.0 Design and function2.1 Design2.2 Functional description2.2.1 Monitoring of tie rod position2.2.2 Overload protection2.2.3 Emergency manual control

3.0 Technical data, main dimensions

4.0 Installation, connection and putting into operation4.1 Installation, accessories4.1.1 Access from the rear4.1.2 Clamping and unclamping cycles4.2 Hydraulic installation4.3 Electrical installation, pin assignment

4.4 Controls4.4.1 Hydraulic and electric controls4.4.2 Hydraulic schematics, flow chart4.4.3 Safety levels4.4.4 Position monitoring, dies and ram

4.4.5 Stroke reverse protection

4.5 Putting into operation4.5.1 Filling with oil4.5.2 Starting and bleeding4.5.3 Setting the operating pressure

5.0 Trouble shooting

6.0 Maintenance and repair

7.0 Technical appendix7.1 List of spare parts

7.2 Installation plan

In order to ensure safe operation for the intended purpose, please read the operatingmanual before installation and before putting the swing sink clamping elements into

operation for the first time!

In order to assist in understanding the functional interrelations of the swing sink clamp-ing elements, especially the need for remedial action if the elements have fallen out ofstep with the others or if the overload protection devices have tripped, a CD-ROM with

computer-animated step-by-step instructions is available as a supplement to this operat-ing manual.

Please request the CD-ROM from [email protected]

January 05- Printed in Germany - - Subject in modification

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1 General information, safety information and manufacturer's declaration

1.1 GeneralThe safety of Hilma-Rmheld swing sink clamping elements has been thoroughly checked. They are de-signed for use as specified in the technical data. If all technical instructions are not observed, the safety ofthe operator and the proper functioning of the machine may be put at risk. Unauthorised modification or al-terations to Hilma-Rmheld carrying consoles is prohibited for reasons of safety. If this instruction is not ob-served, our guarantee will be invalid.

Thorough observance of this operating manual is essential for trouble-free operation of the swing sinkclamping elements. Malfunction during commissioning and during press operation is often due to incor-rect installation or to erroneous operation or control (see chapter 5.0 'Trouble shooting')

1.2 Field of applicationThe Hilma-Rmheld swing sink clamping element is integral part of a hydraulic quick clamping system forpress dies.The swing sink clamping elementmay be installed as a multiple arrangement in the press bed or in the ram

so that in the unclamped position no parts project over the bed upper edge or the lower edge of the ram sothat dies / die carriers may be changed without any impediment.The swing sink clamping element for external clampingmay be installed as a multiple arrangement on theoutside of the press bed or the ram, so that in the unclamped position, the tie rod is flush with the bed orram level and no parts project over the upper edge of the bed or the lower edge of the ram so that dies / diecarriers may be changed without any impediment.

1.3 Operating parametersHilma-Rmheld swing sink elements must not be exposed to higher pressures / forces than those specified.The maximum operating pressure must not be exceeded.

1.4 TemperaturesThe maximum operating temperature for the standard version is 70 C.

1.5 Important safety information- Only use suitable connectors for hydraulic installation (see chapter 4 'Installation').- Tighten fastening screws by applying the specified torque (see chapter 4 'Installation').- Installation and repair work must only be carried out in a depressurized condition.- Specified operating pressures and temperatures must not be exceeded.- When clamping and unclamping operations are carried out, keep your hands well away from

the moving range of the swing sink elements.

Before putting the elements into operation, the operator must be fully trained.Young people under 16 years old must not be allowed to operate the clamps. Staff over 16 years old are al-lowed to operate the consoles under supervision as part of their apprenticeship. The operating instructionsmust be readily accessible. The operator must inform third parties of any danger in the working area.

1.6 Manufacturer's declarationThe swing sink clamping elements have been developed, designed and manufactured in accordance withthe EC Directive 'Machinery' 98/37/EC. The complete declaration is available on request.

2 Design and function

2.1 DesignThe swing sink clamping elements consist of the housing which accommodates the swing mechanism forthe piston, inductive proximity switches for monitoring the unclamping, change-over and clamping positionand the piston with the tie rod.The swing mechanism consists of a guide pin which guides the piston in such a manner that it rotates dur-

ing part of the stroke. The rotating movement is carried out just before reaching or after leaving the upperpiston end position (change-over position).It always rotates to the left, whether the piston is retracting or ex-tending.

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2.2 Functional description

1. Unclamping positionThe piston has completely retracted. Easy die change, as there are no parts projecting above bed or ram le-vel. Proximity switch 2S1 monitors this position.

2. Change-over position for clampingPressure is applied to piston side B. The tie rod has moved through the slot of the clamping point and hasthen rotated by 45. Proximity switch 2S2 monitors this position.

3. Clamping positionPressure is applied to rod side A. The tie rod has once again rotated by 45and has retracted. Follow ing alinear stroke of 5 mm the tie rod is diagonally above the clamping point. The die is clamped. Proximity switch2S3 monitors this position.

4. Change-over position for unclampingPressure is applied to piston side B. The tie rod is extended and then again rotated by 45. Proximity switch2S2 monitors this position.

5. Unclamping positionPressure is applied to rod side A. After a further rotation of 45, the tie rod has again moved throug h the slotof the clamping point and has reached the end position. Proximity switch 2S1 monitors this position. The dieis unclamped.

(For functional and hydraulic schematics and fort he pin assignment of the proximity switches, see chapter4.4.2, hydraulic schematics, flow chart and 4.3 'Electrical installation, pin assignment')

A number swing sink clamping elements in one hydraulic circuit will perform different piston move-ments due to lack of mechanical coupling, varying friction of the components and different lengths ofthe piping (extending of all elements is not synchronous!). Therefore, the piston movements of ALLswing sink clamping elements in one hydraulic circuit must be fully carried out once they have beenstarted, until the change-over position has been reached.

The signals of the proximity switches "Change-over position' and of the pressure switches of ALL elementsmust be available! (See also chapter 4.4.5 'Stroke reverse protection), otherwisethe clamping arms may fall out ofstep, and the swing mechanism, may be damaged (see also chapter 5.0 'Trouble shooting')

Swing sink clamping element

Swing sink clamping element for external clamping

1. Unclamping position 2. Change-over position 3. Clamping position 4. Change-over position 5. Unclamping positionfor clamping for unclamping

Check valve

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2.2.1 Monitoring of tie rod positionIn order to ensure safe functioning of the swing sink clamping elements it is necessary to monitor the un-clamping, change-over and clamping positions, so that signals for die change and machine operation areavailable and any malfunction is indicated immediately. For this purpose, inductive proximity switches are in-tegrated into the cylinder housing. They react to switching positions of the piston rod. The signals for theclamping, change-over and unclamping positions can also be displayed on the control panel, in order to fa-

cilitate trouble shooting in the event of a failure. In the control system, the signals are required together withthe signals emitted by the power unit pressure switches in order to ensure a trouble-free cycle of the swingsink clamping elements.

When using distribution block 5700-015, failures are indicated by LEDs and can be localized.

(For a description of the distribution block, see chapter 4.3 'Electrical installation'.For functional dimensions for the tie rod position, see chapter 3.0 'Technical data, main dimensions'.)

2.2.2 Overload protectionFree swinging movement of the tie rod must be ensured.If there is nevertheless an obstacle in the swinging range of the tie

rod, the swing mechanism is protected by overload protection. Inthe case of a failure, the guide pin which is kept in position byspring-loaded balls will disengage.

(For repositioning the guide pin, see chapter 2.2.3, emergency handcontrol and chapter 5.0 'Trouble shooting')

2.2.3 Emergency manual controlWhen the overload protection has tripped or the swing sink clamping elements have fallen out of step, theguide pin can be repositioned and the tie rods can be reset to give uniform movement by manually rotatingthe guide pin.An external hexagon on the guide pin at the rear of the clamping element and an internal hexagon on the

clamping head of the tie rod provide for manual resetting.

Free access to one of the two hexagons for emergency manual control must be ensured! Access may be achieved by a firmly installed extension to the external hexagon on the guide pin (e.g.by a rod assembly with reversal of the direction or by a cardan joint)Only apply emergency manual control in a depressurized condition!

Overload protection guide pin

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3 Technical data, main dimensions

Swing sink clamping element

In the case of special designs (215x-8xxx) please note the informationon the following drawing!

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Swing sink clamping element for external clamping

In the case of special designs (223x -8xxx) please note the informationon the following drawing!

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4 Installation, connection and putting into operation

4.1 Installation, accessoriesIn order to ensure perfect functioning, the holes for the swing sink clamping elements and the clamping

flanges must be drilled into the press bed and ram and into the die taking due account of the indicated di-mensions and tolerances.

Guides, end stops and fasteners, respectively, are required as limiting measures for the die.

Drilled Hole for Swing sink clamping element Drilled hole for flange

View Y View X

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4.1.1 Access from the rear Hydraulic ports A and B must be easily accessible for instal-lation, maintenance and dismantling purposes. If the in-

stallation space is tight, the swing sink clamps may beprovided with an O-ring flange connection, in order toensure easy replacement.

Furthermore, rotation of the guide pin must beassured in the case of failure, if necessary bymeans of a firmly installed extension (see chap-ter 2.2.3 'Emergency manual control')

4.1.2 Clamping and unclamping timeWhen changing dies, the time required forhydraulic clamping and unclamping is rathershort. The capacity of the power unit must bedesigned so that the clamping and unclamping

cycle takes between 10 and 30 seconds. Shortercycles are not recommended for the reason offunctional safety.

Clamping and unclamping cycle:

Qp = (V * z * 60) / (t * 1000) in sec

t = Clamping / unclamping cycle (s)V = Oil consumption / swing sink

clamp (cm3)

z = Number of swing sink clampsQp = Pump capacity (l/min)

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4.2 Hydraulic installationConnect the swing sink clamping elements using DIN 2353 screw fittings (heavy design) (for connections,see chapter 3 'Technical data, main dimensions').The hydraulic pipework on the machine side must be of sufficient size (type 2154: 8x2 DIN 2391-St35 NBKor larger; types 2155, 2156, 2235 and 2237: 12x2.5 DIN 2391-St35 NBK or larger) must be installed in ac-cordance with the specifications (DIN EN 982) and must conform to up-to-date practice for high-pressure

hydraulics.- Pipes should be as short as possible; pipe bends should have a large radius.- Neat installation is essential for trouble-free operation of the system.- Make sure that the pipe ends are free from burrs and that pipes, high-pressure hoses and screw fittingsare cleaned and blown through.

- Protective plugs should only be removed immediately before connecting the hydraulic system.- Swing sink clamps that belong together should be connected to manifold blocks, series connection shouldbe avoided.

- Pipes leading to the power unit should be of sufficient diameter to avoid back pressure.- Area ratio A : B = 1 : 1.,5 ;max. back pressure to connection B = 50 bar- Provide each hydraulic port with a pressure gauge connection to enable check and adjustment ofoperational data.This allows the locality of functional errors to be established quickly.

- Pipes should be fastened using pipe clamps.

In case of doubt, please send installation schematics for check ([email protected])

4.3 Electrical installation, plug assignmentEach swing sink element is provided with 3 proximity switches for monitoring the clamping, change-over andunclamping position.Clear, easy-to-maintain installation is achieved when the connecting cables are connected to a distributorblock on the bed or on the ram. From here, the cables of all connected swing sink clamping elements arebundled and connected to the control cubicle in the form of 16-wire cables.

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4.4 Controls

4.4.1 Hydraulic and electrical controlsThe swing sink clamping elements are controlled by a power unit which, for reasons of safety, is completelyseparated from the hydraulic system of the machine.As oil is only required for clamping and unclamping, the power unit operates intermittently. A pressure reliefvalve protects the hydraulic systems against overpressure. When the operating pressure (max. 400 bar) isreached, a pressure switch switches the motor off. If pressure drops 10% below the set value same pres-sure switch causes the motor to start again.The valves are of the seat valve type. The 24V solenoids are designed for 100% duty and deenergizedwhen the swing sink clamping elements are clamped. This ensures a long service life and furthermore, theclamping force is maintained even in the event of power failure.

4.4.2 Hydraulic schematics, flow chart

Swing sink clamping element type 215x

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Swing sink clamping element for external clamping type 223x (with or without pilot-controlled check valve)

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4.4.3 Safety levelsAlthough malfunctions seldom occur on hydraulic quick clamping systems, failure of a component cannot becompletely excluded.In order to avoid the consequences of such a failure having an impact on the clamping safety, three safetylevels are provided, and at least two of them should be installed.

4.4.4 Position monitoring, die and ramIn order to protect the dies and the swing sink clamping elements, the correct die position must be moni-tored by a proximity switch.

Only once the die is correctly centred can clamping be carried out.The ram, too, must be provided with a proximity switch which permits clamping after the ram is in contactwith the die surface.

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4.4.5 Stroke reverse protectionThe electrical control must be designed in a way that during clamping or unclamping stroke reversal is notpossible due to power failure or due to actuation of the EMERGENCY-OFF switch before ALL clampingarms have been fully retracted or extended (signal by proximity switches).

4.5 Putting into operation

Read the operating manual before putting the system into operation!

When all hydraulic and electrical connections have been checked the system can be put into operation.As the possibility that the swing sink clamping elements might fall out of step cannot be excluded, a test runof all functions without a die is carried out.In the test run / manual operation the position monitoring of die and ram must be circumvented (selectorswitch).In the operating position of the selector switch (no test run) clamping and unclamping is initiated by a push-button and will then take place automatically.

ATTENTION:During all the time that the die is clamped, the pump unit must not

be switched off. This also applies to week-ends. Exception: the die is closed, orthe upper half of the die is mechanically locked!

4.5.1 Filling with oilOnly use clean, new hydraulic oil HLP 32 DIN 51524, viscosity 150 VG 32 as per DIN 51519.

4.5.2 Starting and bleedingBleed the complete system with the pump running at low pressure (=20 bar, in the case of back pressurepossibly higher) at the highest point. In order to achieve this, slightly open a screw fitting until the oil emerg-ing is free from bubbles.

Operate all swing sink clamping elements several times until all movements are free from jerks and are

completed in the calculated time.

Check the hydraulic installation for tightness. Visually check all pressurized pipes, hoses, screw fittings andclamping elements.

Check the oil level when the swing sink clamps are in an unclamped position. Refill with hydraulic oil, if nec-essary.

ATTENTION: When clamping and unclamping operations are carried out, keepyour hands well away from the moving range of the swing sink elements.DANGER OF INJURY!

4.5.3 Setting the operating pressure

Set the pressure switch for pump control to the highest value. Switch on the pump. Set the operating pressure on the pressure relief valve approx. 10% above the desired operating

pressure. Reset the pressure switch for pump until the pump switches off. Switch the pump on and off several ti-

mes, thereby setting the pressure switch to the desired operating pressure.

ATTENTION: In order to prevent continuous running of the pump which mightcause damage, the pressure relief valve must be set to a value which is approx.

10% above the tripping point of the pressure switch!

Set the pressure switch for the machine controls approx. 15% below the operating pressure.

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5 Trouble shootingThe swing sink clamping elements have left our premises in perfect condition. All functions have been tested,and necessary adjustments have been made.If any malfunction should occur even though the conditions stipulated in chapter 4.0 (Installation and puttinginto operation) have been duly observed, please try to establish the cause using the table below.

ATTENTION:Only carry out repairs on the hydraulic system when no die is in themachine, the system is switched off and all circuits have been depressurized bymanually operating the directional valves. Install the dies once all functions havebeen tested and they perform impeccably!

Failure 1 The clamping pressure is not maintained. The pump is running frequently.

Cause Loose screw fitting.Remedial action Find leakage. Tighten the screw fitting in a depressurized condition.

Cause Loose, dirty directional valve. Leakage from P to R.Remedial action Check in which circuit pressure falls. Dismantle the directional seat valve and clean or

replace it.

Cause Seals in the swing sink element, in the pressure switch or the directional seat valve areworn out.

Remedial action Have seals replaced by qualified personnel or send clamping element for repair.

Cause Check valve in the valve block is loose.Remedial action Flush the check valve. To do this, manually actuate the directional seat valve (clampingcircuit P) while the pump is switched on. If still loose, replace the check valve.

Failure 2 The clamping arms have fallen out of step or have disengagedIn order to assist in understanding the functional interrelations, a CD-ROM with computer-animated

step-by-step instructions is available.

CauseThe tie rod has been impeded during swinging (e.g. collision dueto incorrect die position => disengagement, see chapter 2.2.2,'Overload protection'), or the swing movement was stopped be-fore reaching the change-over position (=> clamping arms havefallen out of step, see chapter 2.2 'Functional description').The tie rod of the swing sink clamping element has disengagedand/or has fallen out of step.

Remedial action

1.(Die still in the machine)Actuate (unclamp) the system with the die closed in sucha way that the tie rod which has fallen out of step clampsthe die (there may be no signal from the proximity switch).All the other tie rods are in the unclamped position (signalfrom the proximity switch 'Unclamping position').

2.Switch off the power unit and depressurize all clampingcircuits by manually operating all directional seat valves.

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3.Manually rotate the guide pin of the swing sink clamp-ing element which has fallen out of step until the signal ofthe proximity switch "clamped" lights up. Then rotate theguide pin by another 90.

ATTENTION:The guide pin has 2 positions of engagement which arestaggered by 180.Disengaging torque:type 2154 10 Nmtype 2155 / 2235 20 Nmtype 2156 / 2237 30 Nm

4. Switch on the power unit. The command 'Unclamp'causes the tie rod move into the unclamping position.

5.Take out the die.

6.Switch off the power unit and depressurize all clampingcircuits.

7. Ensure that the guide pin of the swing sink clampingelement is engaged (emergency hand control).).

=> If all tie rods are in the same position and the signal ofthe proximity switch is "unclamped" for all swing sinkclamping elements, the problem has been solved.If the clamping arm having fallen out of step does notshow the 'unclamped' signal or is positioned at 90 posi-tion towards the other clamping arms, continue with para-graph 8.

8.1 Switch on the power unit and move all swing sinkclamping elements in test operation in the change-overposition.Insert a blank for blocking the clamping arm which hasfallen out of step.Clamp and unclamp all clamping elements until synchro-nous operation of all clamping arms is achieved (normally1x clamping + 1x unclamping + back into the change-over

position)

or

8.2If insertion of a blank is not possible due to restricted space, the clamping arm which has fallen out ofstep can be uncoupled hydraulically (undo hydraulic connections and close them). Clamp and unclamp theremaining clamping elements as described in 8.1 until simultaneous movement is again achieved.

In order to assist in understanding the functional interrelations, a CD-ROM with computer-animatedstep-by-step instructions is available.

Please request from [email protected]

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Failure 3 Tie rod position monitoring with permanent signal or without a signal.

ATTENTION: In the case of malfunction of the tie rod position check the function of the proximity switchesusing an initiator testing device on the terminal box (see chapter 4.3 'Electrical installation'). Then check theevaluation electronics.

Cause for a permanent signal Short circuit in the control line, proximity switch defective or switching in-terval too long.

Cause for no signal Control line interrupted, proximity switch defective or guide pin disen-gaged.

Remedial action Check the electrical installation and the swing sink clamping element,have it repaired by HILMA experts, if necessaryIf the guide pin has disengaged, see failure 2.

6 Maintenance and repairHydraulic valves are sensitive to dirt. No impurities must get into the hydraulic oil. It is recommended thatthe oil be changed once a year.When carrying out routine maintenance work on the press:- visually check the electrical connections (plug, cable) for damage- check the hydraulic system for tightness.For spares and installation sketches, see chapter 7 (Technical appendix).

In the case of failure it is recommended that the swing sink clamping element is replaced, in order to avoiddown times. The repair can then be made off the press (if necessary in our premises in Hilchenbach).

Repairs to swing sink clamping elements, especially to seals, on the clamping and swing mechanism andon the position control must be carried out by qualified staff only!

ATTENTIONBefore dismantling swing sink clamping elements, undo all electrical and hydraulic connections.Swing sink clamping elements must only dismantled with the tie rods in the unclamped position!

After changing a swing sink clamping element, the element must be clamped and un-clamped several times without the die, in order to ensure bleeding though the power unit (this also applies ifhydraulic connections have been disconnected.For putting into operation, see chapter 4 ('Installation and putting into operation')

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7 Technical appendixThe technical appendix comprises the list of spare parts and the installation plans.

7.1 List of spare parts

Position Designation

010 Complete set of seals020 Proximity switch030 Build-in plug

040 Guide pin050 Piston060 Balls for overload protection

070 Balls for guide pin080 Springs for overload protection090 Check valve for swing sink clamping element for external clamping

When ordering spare parts, please indicate the designationof the spare part, the complete type number(e.g. 2154-160 or 2156-8005) and the check number(e.g. 26-03X) des of the swing sink clamping elementBoth numbers are engraved on the front of the fastening flange.

If repair to the swing sink clamping elements, especially in the event of damage to the seals and the swingmechanism, we recommend that the defective swing sink clamp is sent to our Hilchenbach premises for re-pair!

7.2 Installation plan

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MANUFACTURER'S DECLARATION

in conformity with directive

'Machinery' 98/37/EC

dated June 22, 1998

We hereby confirm that the

swing sink clamping elements

types2154-160 / 2154-2002155-160 / 2155-2002156-160 / 2156-200

215x-8xxx2235-310 / 2235-4102237-310 / 2237-410

223x-8xxx

as supplied by us have been specifically designed for installation in a machine taking due account of standard DIN-

EN 294, and that they must only be put into operation after the conformity of the machine with the EC directives has

been demonstrated.

The design of our products is in accordance with DIN EN 982, DIN 24346 and EN 60204-1.

HILMA-RMHELD GmbH

2150e

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